Processing Electrode Jet Eccentricity for Curved Hole Machining

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Solution Overview

Problem

Existing electromechanical machining methods for forming curved holes in difficult-to-machine materials, such as gas turbine rotor blades, require complex electrode configurations, including fluid lead-out portions, which complicate the process.

Innovation Solution

An electromechanical machining method that forms curved-shaped processing holes by feeding an electrolytic solution through an inner channel of a processing electrode and jetting it from an outlet opening, with a current density or flow velocity distribution eccentric to the axial center, allowing the electrode to curve without a fluid lead-out portion, thereby simplifying the electrode configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a fluid lead-out portion is provided on the electrode to enable curved hole formation, then the curved hole can be formed, but the electrode configuration becomes complicated

Engineering Contradiction:

Improvecurved hole formationVSAvoidelectrode configuration

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the fluid lead-out portion from the electrode configuration. Instead of using a complex electrode with integrated fluid lead-out structures, the patent uses a simple straight electrode combined with external fluid supply nozzles positioned near the electrode tip to achieve curved hole formation through controlled electrolytic solution flow

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention segments the curved hole formation function from the electrode body. The electrode remains a simple straight conductor, while the curving function is achieved separately through externally controlled electrolytic solution jetting from multiple nozzles positioned at different locations around the electrode tip

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the current density distribution is made eccentric to achieve curved hole formation, then the machining precision is improved, but the control complexity increases

Engineering Contradiction:

Improvecurved hole shape controlVSAvoidcurrent density control

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention replaces complex electrical control systems that would be needed to generate eccentric current density distributions with a simpler fluid control system. By controlling the flow velocity distribution of electrolytic solution from externally positioned nozzles, the patent achieves the same curved hole formation effect without the complexity of variable electrical field control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the control parameter from electrical (current density distribution) to fluid mechanical (flow velocity distribution). By adjusting the flow rate and position of electrolytic solution jets, the patent achieves precise control over the curved hole formation path without needing to complexly modulate electrical parameters

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the easy formation of curved holes in workpieces without complicating the electrode configuration, improving machining efficiency and precision by controlling the current density and flow velocity distributions.

Implementation Method 1

forming a curved-shaped processing hole in a workpiece by electromechanical machining

Methodology Applied

Scientific EffectElectromechanical machining:

Implementation Method 2

jetting the electrolytic solution from an outlet opening of the inner channel disposed on a tip surface of the processing electrode, a step of applying a potential difference between the processing electrode and the workpiece

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Data Source

PatentUS11376681B2Electromechanical machining method, method of manufacturing perforated material, processing electrode, and electromechanical machining system

Publication Date: 2022.07.05 MITSUBISHI POWER LTD

AI summary

A method of forming a curved-shaped processing hole in a workpiece by electromechanical machining includes a step of feeding an electrolytic solution through an inner channel of a processing electrode and jetting the electrolytic solution from an outlet opening of the inner channel disposed on a tip surface of the processing electrode, a step of applying a potential difference between the processing electrode and the workpiece while jetting the electrolytic solution from the outlet opening of the processing electrode, and a step of forming the curved-shaped processing hole in the workpiece. In the jetting step, at least one of a current density distribution on the tip surface of the processing electrode or a flow velocity distribution of the electrolytic solution jetted from the outlet opening is eccentric to a downstream side of a curving direction of the processing hole with respect to an axial center of the tip surface.